SUNDYNE GEARBOX 311

SUNDYNE GEARBOX 311

HEART OF SUNDYNE UNIT

150 KW FULL LOAD RATING

INTERNAL LUBE PUMP - BI-DIRECTIONAL

 OPTIONS GEARBOX 311

EXTERNAL LUBE

HEAT EXCHANGER

SUMP HEATER

PROBES

SWITCHES
SUNDYNE GEARBOX 311

MODULAR DESIGN PROVIDES A

“CUSTOM” COMBINATION OF
GEARS AND BEARINGS FOR
EACH APPLICATION

• WIDE RANGE OF GEAR RATIOS

MATCH THE IMPELLER SPEED TO
PROCESS REQUIREMENTS
• HIGH SPEED BEARING OPTIONS
PROVIDE STABLE
ROTORDYNAMICS
• SIMPLE ASSEMBLY AND DISASSY
WITH A MINIMUM NUMBER OF
PARTS, SIMILAR TO MOST OTHER
PUMP BEARING BOX ASSEMBLIES
SUNDYNE GEARBOX 311

INTEGRAL GEARBOX, PROCESS

END, AND MOTOR MOUNTING

• COMPACT PACKAGE HAS SMALLER

FOOTPRINT AND REDUCED
INSTALLATION COSTS
• SHORT SPANS BETWEEN BEARINGS
MAKE A MORE ROBUST DESIGN
WITH LESS VIBRATION
• SELF-CONTAINED PRESSURIZED
LUBRICATION SYSTEM, WITH SPIN
ON FILTER
 LUBE PUMP in SUNDYNE GEARBOX 311

50 and 200 horsepower

SHAFT DRIVEN REVERSIBLE
 LUBRICATION

LIGHT TURBINE OIL IS PREFERRED LUBE OIL,

A WORD ABOUT ATF,
NO INERT ADDITIVES,
VISCOSITY GRADES:
 RECOMMENDED GEARBOX LUBRICANTS

• ATF TYPE DEXTRON III

IS NOT ACCEPTABLE!

• ISO 32/46 GRADE GENERAL PURPOSE OIL

IS THE RECOMMENDED LUBE OIL!
• WIDELY AVAILABLE
• LOW COST
• COMMONLY USED THROUGHOUT FACTORIES

• SYNTHETIC OIL RECOMMENDED FOR EXTREME CONDITIONS

VISCOSITY - TEMPERATURE FOR
GEARBOX LUBRICANT

ISO VG 32
ISO VG 46
 LUBRICATION

SPEC SHEETS CAN BE PROVIDED

CHANGE EVERY 6 MONTHS

CHANGE IF COLOR CHANGES (and investigate root cause:

contamination, burn…)
 GEARBOX “2 STEPS”

Input
Shaft Input
Idler Gear
Input
THE OFFSET BETWEEN INPUT Gear

AND OUTPUT SHAFTS FOR

A SINGLE GEAR SET CAN
BE ELIMINATED BY THE Idler
Shaft
USE OF AN IDLER SHAFT Idler Output
Output Gear
Gear
Output
Shaft

# TeethInput _ Gear # TeethIdler _ Output _ Gear

Output _ RPM  Input _ RPM  
# TeethOutput _ Gear # TeethIdler _ Input _ Gear
 SUNDYNE GEARBOX “2 STEPS”

WHAT MAKES UP A SUNDYNE GEARBOX?

- GEARS AND SHAFTS

- BEARINGS

- BEARING PLATE

- UPPER AND LOWER

HOUSINGS

- SEALS, UPPER AND LOWER

- SHAFT DRIVEN LUBE PUMP

AND PRESSURIZED LUBE SYSTEM
 SUNDYNE GEARBOX “2 STEPS”

WHAT MAKES UP A SUNDYNE GEARBOX?

- GEARS AND SHAFTS

- BEARINGS

- BEARING PLATE

- UPPER AND LOWER

HOUSINGS
- SEALS, UPPER AND
LOWER
- SHAFT DRIVEN LUBE
PUMP AND PRESSURIZED
LUBE SYSTEM
 SUNDYNE GEARBOX “2 STEPS”

WHAT MAKES UP A SUNDYNE GEARBOX?

- GEARS AND SHAFTS

- BEARINGS

- BEARING PLATE

- UPPER AND LOWER

HOUSINGS
- SEALS, UPPER AND LOWER

- SHAFT DRIVEN LUBE PUMP

AND PRESSURIZED LUBE
SYSTEM
SUNDYNE GEARBOX 311
LUBE OIL SCHEMATIC
SUNDYNE LMC-311P
 Lube System Pressure

• AFFECTED BY OIL VISCOSITY AND TEMPERATURE

• AS TEMP INCREASES, OIL VISCOSITY AND PRESSURE DECREASE
• AFFECTED BY BEARING CONFIGURATION(PRESSURE & FLOW)
• TILT-PAD BEARINGS USE MORE OIL BUT LESS PRESSURE THEN PLAIN
• AFFECTED BY INPUT SHAFT SPEED
• DIRECTLY AFFECTS SHAFT DRIVEN LUBE PUMP OUTPUT
• REGARDLESS OF CONFIGURATION, OIL PRESSURE SHOULD
REMAIN STEADY DURING OPERATION
• 4½, 9 AND 12½ GPM (1, 2 & 2.7m3/h) PUMP CAPACITY
• ABOVE 18,000 RPM BEARING CONFIGURATION MAY CHANGE
• ABOVE 8,000 RPM HEAT EXCHANGER RECOMMENDED
 OIL PRESSURE/ TEMPERATURE

PRESSURE MEASURED BY GAUGE OR SWITCH, IN GEARBOX

LUBE GALLEY

MONITOR TEMPERATURE IN SUMP

MAINTAIN 60-70°C IN THE SUMP (ALARM: 80°C, TRIP:

90°C)
(50-60°C AT THE GEARBOX INLET)

PRE-LUBE REQUIRED FOR 400HP

RELIEF VALVE
 WHY DOES A GEARBOX NEED
A LUBE SYSTEM ?

• REDUCE FRICTION BETWEEN CONTACT SURFACES OF

GEARS AND BEARINGS

• KEEP BEARINGS AND SEALS COOL AND CLEAN (VIA

HEAT EXCHANGER AND FILTER)

• PRODUCE PRESSURIZED OIL FILM TO ELIMINATE

CONTACT IN HYDRODYNAMIC BEARINGS
 ON SITE CASE

•Unit feated with an oil-water heat exchanger

•Machine run for 20 minutes approx

•Sudden noise and vibration

•Important buffer liquid leakage out of the pump, smoke

through port 1
ON SITE CASE - inspection
 ON SITE CASE – Troubleshooting

•No delta oil temperature up- and downstream the Heat

Exchanger

•Water cooling outlet valve found closed

•Oil burned, so no film could be build between high speed

shaft and journal bearing

•Estimated cost of the incident: €10.000

 STANDARD
LUBE SYSTEM COMPONENTS

• INTERNAL OIL RESERVOIR

• INTERNAL SHAFT DRIVEN LUBE PUMP

• EXTERNAL SUNDGARDTM OIL FILTER

• LUBE SYSTEM PRESSURE GAUGE

• EXTERNAL HEAT EXCHANGER WHEN REQUIRED

(SUPPLIED WITH OIL TEMPERATURE GAUGE)
WHEN IS A HEAT EXCHANGER A
STANDARD ITEM ?

• GEARBOX SPEEDS GREATER

THAN 8,000 RPM (INCLUDES
MOST SUNDYNE GEARBOXES)

• PROCESS TEMPERATURES
ABOVE 300 DEG F(150°C)

• WHEN A NOISE BLANKET IS

SUPPLIED

• STANDARD IS WATER COOLED

 OPTIONAL
LUBE SYSTEM COMPONENTS

• EXTERNAL (AUXILIARY) LUBE PUMP FOR PRE-LUBE

ALWAYS WITH TILT-PAD BEARINGS & 350/400HP GBX

• HEAT EXCHANGER (WATER OR AIR COOLED)

• SUMP OR IN-LINE HEATER

• PRESSURE AND TEMPERATURE TRANSMITTERS

AND/OR SWITCHES

• EXTERNAL OIL RESERVOIR (DRY SUMP DESIGN)

• DUAL FILTERS WITH DELTA-P INDICATION

• 3M @ 200 -RATIO
• EXTENDS OIL, BEARING, SEAL, AND
GEAR LIFE WITHOUT AFFECTING THE
ADDITIVES IN THE OIL
• ACHIEVES HIGHER FILTRATION LEVEL
WITH MINIMAL PRESSURE DROP
• 3M PARTICLE SIZE AND A FILTRATION LEVEL OF
200 (-RATIO) MEETS BALL BEARING
MANUFACTURER’S STANDARDS FOR MAX LIFE
EXPECTANCY
• SUPPORTED GLASS FIBER PLEATS MEANS
LARGER SURFACE AREA AND LOWER PRESSURE
DROP THROUGH THE FILTER. IT CAN CAPTURE
MORE PARTICLES W/O DEGRADATION IN
PERFORMANCE
 GEARS

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA CLASS 11 RECOMMENDED FOR COMPRESSORS AND

AEROSPACE APPLICATIONS

80% OF OUR GEARS CONFORM TO AGMA CLASS 12

 SUNDYNE GEARBOX

HIGH QUALITY GEARS BY DESIGN

• GEARS DESIGNED TO AGMA CLASS 11
(AMERICAN GEAR MANUFACTURERS ASSOCIATION),
SUGGESTED FOR COMPRESSOR AND AEROSPACE
APPLICATIONS:

APPLICATION AGMA SUGGESTED CLASS

AEROSPACE ENGINE ACCESSORIES 10-13

• MORE THAN 30 YEARS OF GEAR

PRODUCING EXPERIENCE
• EVERY LOT OF GEARS SUBJECTED TO
STRINGENT QUALITY INSPECTIONS,
INCLUDING SAMPLE SECTIONING,
MOUNTING, AND HARDNESS
TESTING
• MANUFACTURED AT OUR ARVADA FACTORY
 GEARS

GEARS RATIOS (LMX/BMX):

• MAX PUMP SPEED = 24,724

• MAX COMPRESSOR SPEED = 34,000

 GEARS

DEFINITIONS:

• PITCH = DISTANCE BETWEEN ADJACENT TEETH OF CORRESPONDING

POINTS

• PITCH DIAMETER = DIAMETER AT WHICH PITCH IS MEASURED

• LEAD = ANGLE OF TOOTH FROM END TO END

• PROFILE = THEORETICAL SHAPE OF TOOTH FACE

• COMPOSITE ERROR = TOTAL OF ALL ERRORS INCLUDES; LEAD, PROFILE,

RUN OUT, TOOTH TO TOOTH & ETC
 GEARS

NOMENCLATURE:
Lead
Checking
True
Involute
Profile
Active
Profile

Profile
Pitch
Error
 GEARS

MANUFACTURE / MATERIALS:

• MOST GEARS HARDENED AND GROUND. AISI 8620

• PROCESS: CUT BLANK, TURN, SHAPE TEETH, HEAT TREAT, GRIND

AND INSPECT

• INTEGRAL GEARS-9310 AIRCRAFT QUALITY

• CARBURIZE TEETH AND HARDEN SHAFT IN SAME OPERATION

 GEARS

SPUR GEAR:
GEAR TOOTH HARDNESS

HARDNESS PROFILE IS
CRITICAL TO GEAR
PERFORMANCE:

• HARD EXTERIOR
PROVIDES CONTACT
STRENGTH AND LONG
WEAR LIFE

• SOFT INTERIOR MAKES

TOOTH TOUGHER TO
RESIST BENDING
STRESSES
GEAR INSPECTION

• DIMENSIONAL
INSPECTION BY RUNNING
AGAINST A MASTER GEAR

• SECTIONING OF SAMPLE
TO VERIFY HARDNESS
PROFILE
 ANTI-FRICTION BEARINGS
(Ball and Roller)

USED WHERE SPEEDS AND LOADS ARE RELATIVELY LOW,

USUALLY AT INPUT SPEEDS AND SOME IDLER SHAFT
SPEEDS

THE TYPES USED ARE:

• CONRAD (OR DEEP GROOVE) BALL BEARINGS

• ANGULAR CONTACT BALL BEARINGS
• ROLLER BEARINGS
 BALL BEARINGS

PART NUMBER & LOCATION:

UPPER LOWER UPPER LOWER
GEARBOX
INPUT INPUT IDLER IDLER
37 kW (322) 21-008 21-008 N/A N/A
150 kW (311) 21-008 21-008 21-133 21-008
275 kW (331) 21-118 21-117 Journal Journal
315 kW (341) 21-119 21-120 Journal Journal

BALL BEARING DEFINITION:

PART NO. TYPE No. BALLS CAGE
21-008 Conrad 8 Steel

21-133 Conrad 11 Polyamid

21-117 Spherical roller 2x 19 Steel
21-118 Spherical roller 2x 14 Steel
21-119 Spherical roller Steel
21-120 Spherical roller Steel
BALL BEARINGS

21-008
 HYDRODYNAMIC BEARINGS

• THIN, PRESSURIZED OIL FILM SUPPORTS SHAFT, MAKES A

“NON-CONTACT” BEARING WHILE RUNNING

• SIMPLE EXAMPLE IS PLAIN JOURNAL BEARING

– MOST COMMON IN PUMPS

• TILT-PAD JOURNAL IS MORE COMPLEX AND COSTLY

– MOST COMMON IN COMPRESSORS, WHERE RADIAL LOADS
ARE LOWER, PREVENTS OIL WHIRL, PROVIDES ROTOR
STABILITY

• BOTH SOLID AND TILT PAD AVAILABLE FOR RADIAL AND

THRUST POSITIONS
 PLAIN THRUST BEARING WITH TILTING
PAD OR PLAIN JOURNAL RADIAL BEARING

Tilting Pad Journal

Plain Journal

Plain Thrust
 HYDRODYNAMIC BEARINGS

PLAIN THRUST WITH TILTING PAD OR PLAIN RADIAL

JOURNALS:
 HYDRODYNAMIC BEARINGS

TILTING PAD THRUST WITH TILTING PAD OR PLAIN RADIAL JOURNALS:

 HYDRODYNAMIC BEARINGS

PLAIN THRUST WASHERS:

 HYDRODYNAMIC BEARINGS

THRUST WASHERS:
 HYDRODYNAMIC BEARINGS

PLAIN JOURNAL-MOST COMMON IN PUMPS, MOST COST

EFFECTIVE
TILT-PAD JOURNAL-MOST COMMON IN COMPRESSORS-
PREVENT OIL WHIRL PROVIDE ROTOR STABILITY

PLAIN THRUST WASHER-MOST COST EFFECTIVE-100 PSI

LOAD ON BEARING
HIGH THRUST WASHER TO 450PSI
AXIAL TILT PAD THRUST-HIGH SUCTION PRESSURE-400PSI
ON BEARING
 THRUST BEARING SELECTION

THRUST - FUNCTION OF IMPELLER GEOMETRY AND

SUCTION PRESSURE

CONCENTRIC BOWL

Z-SERIES: IMPELLER: TOWARD SUCTION

FULL EMISSION: IMPELLER: TOWARD SUCTION

COMPRESSORS-SUCTION PRESSURE: TOWARD GEARBOX

 THRUST BEARING SELECTION

FOR PARTIAL EMISSION PUMPS (SERIES NOT INCLUDED):

SUCTION PRESSURE (PSIG)

STANDARD HIGH CAP TILTING PAD THRUST
SUNDYNE UNIT WASHER THRUST WASHER BEARING
LMV-311 0 - 200 201 - 450 451 - 1000
LMV-322 0 - 200 201 - 450 N/A
LMV-331 0 - 200 201 - 450 451 - 1000
 RADIAL BEARING SELECTION

SELECTION BY COMPUTER

BASED ON LOAD, SPEED, IMPELLER, ETC

151A – BEARING
 FIELD EXTENSION

CONTINUOUS POWER SUPPLY

VOLTMETER

-24V
 GEARBOX SEALS

TWO MAIN TYPES:

• LIP AND LABYRINTH SEALS

– USED FOR INPUT SHAFTS

– LOW SPEEDS
– MOSTLY SUBJECTED TO LUBE SPLASH/SPRAY

• MECHANICAL SEALS

– USED FOR OUTPUT SHAFTS

– HIGH SPEEDS
– SEALS A BODY OF FLUID
 GEARBOX SEALS

OUTPUT SEAL-CARBON VS TUNGSTEN CARBIDE

COMMON FOR ALL GEARBOXES

REVERSE PRESSURE

BE SURE PORT #1 IS ALWAYS OPEN

GEARBOX SEALS
GEARBOX SEAL
 GEARBOX SEALS

NEW SUNDSTRAND GEARBOX SEAL :

36SDA
CARBON
DETAIL
COMPRESSORS

PUMPS
Obsolete
21RE
33REA
SE04AA53G
 MECHANICAL GEARBOX SEAL LAYOUT

Gearbox Oil Rotating

Face

High
Speed
Stationary Shaft
Face
Seal Drain
Cavity
(Port 1)
REVERSE PRESSURE CAPABILITY TO GUARD
AGAINST PROCESS SEAL FAILURE
 SUNDYNE PUMP GEARBOXES

FEATURE BENEFIT
- Over 40,000 units installed since 1962
• Reliable proven gearbox
- AGMA class 11 gears, wide range of ratio’s
• Excellence in Design
- Supported by Plain or Tilt Pad journal bearings
• Stiff high speed shaft
- Bearing span 185 mm, overhang 127 mm
- Compact rugged design
• High speed shaft assembly
- Reduces radial loading
- Reduces vibrations and deflections
- Reliable integral pressurized lubrication system
• Self-contained lube system
- Closed wet sump circuit with filter, cooling and controls
- Additional optional instrumentation is possible
- Simplifies maintenance
• Gearbox exchange program
- Minimizes downtime
- Allows purchasing / maintenance to be used
more productively.
CUSTOM PACKAGING
FEATURES AND OPTIONS